Composite hockey stick handle with resilient shroud

ABSTRACT

A hand-held implement grip and protectant, preferably for a hockey stick, is described. The invention mainly consists of a blade attached to a composite shaft integrally enshrouded with a rubber sheath. A method of forming the same is also provided as laying up a number of sheets of composite material, wrapping those sheets about a mandril, enshrouding the layup with a rubber sheath, vulcanizing the combination, removing the mandril, and inserting a blade therein.

FIELD OF THE INVENTION

[0001] This invention relates to hand-held implements, especially sportsequipment, such as hockey sticks. More specifically, the instantinvention is directed to a hockey stick handle formed from compositematerial having an integrally formed outer elastomeric shroud to protectthe composite material and improve gripping ability.

BACKGROUND OF THE INVENTION

[0002] The necessity for adequately gripping hand-held implements hasbeen a long-known and recurring problem. A variety of grips have beenexplored, but problems still persist. Although it is known to include arubberized grip about the handle of an implement, certain drawbacksstill exist.

[0003] One problem encountered with prior art gripping means (such asU.S. Pat. Nos. 5,050,289 and 5,005,254) is the slippage of the gripvis-á-vis a handle. Whether a grip is glued to a handle orfriction-fitted, such rubberized grips have a tendency to dislodge froma shaft. Furthermore, the longer the shaft, and the longer the gripvis-á-vis the shaft, the greater the likelihood of the grip rolling upon itself or slipping. Many attempts have been made to correct thisproblem, but to no avail. Ultimately, the hand-held implement is eitherreplaced, or the grip is replaced, wasting much time and material.

[0004] Another problem involves the now frequent use of hockey stickshafts formed from composite material. “Space-age” materials, such asKevlar®) boron and graphite, while extremely strong in compression,tension and flexing, have been found to be susceptible to fracture whensharply impacted, such as by a hockey puck or another hockey stick.

[0005] It is desirable therefore to provide a hand-held implement with aresilient grip capable of extending a greater distance along the hockeystick shaft, and providing a grip that endures greater impacts andpressures without fracture or slippage.

[0006] One particular application where a shock damping is desirablealong an entire shaft and where a grip is required to adhere strongly isthat of a hockey stick. Currently, hockey stick grips tend to be justnear the top of a shaft and are of a short length. If extended furtherdown the shaft, or preferably all the way down the shaft, the grip tendsto slip, roll or bunch in the prior art. To overcome these problemswould be a great benefit to the sport and overall safety.

[0007] The following prior art reflects the state of the art of whichapplicant is aware and is included herewith to discharge applicant'sacknowledged duty to disclose relevant prior art. It is stipulated,however, that none of these references teach singly nor render obviouswhen considered in any conceivable combination the nexus of the instantinvention as disclosed in greater detail hereinafter and as particularlyclaimed. INVENTOR ISSUE DATE PATENT NO. 2,201,706 Sukohl 05-21-19402,649,133 Just 08-18-1953 2,674,557 Boggs 04-06-1954 2,964,065Haroldson, et al. 12-13-1960 3,020,192 Stephens, et al. 02-06-19623,125,478 Pratt 03-17-1964 3,606,326 Sparks 09-20-1971 4,016,640 Briggs04-12-1977 4,080,879 Hoden, et al. 03-28-1978 4,134,198 Briggs01-16-1979 4,273,601 Weingart 06-16-1981 4,579,617 Oberg, et al.04-01-1986 4,923,541 Burger 05-08-1990 5,005,254 Uffindell 04-09-19915,024,712 Lecourt, et al. 06-18-1991 5,050,289 Uffindell 09-24-19915,373,616 Biersdorf, et al. 12-20-1994 5,458,330 Baum 10-17-19955,655,981 Reed 08-12-1997

[0008] The prior art listed above, but not specifically discussed, teachgripping devices and further catalog the prior art of which theapplicant is aware. These references diverge even more starkly from thereferences specifically distinguished above.

SUMMARY OF THE INVENTION

[0009] This invention is directed toward addressing the problems ofproviding an anti-fracture gripping means to an elongate member, such asa hockey stick shaft, wherein that gripping means will protect theunderlying composite and still will be substantially free from unwantedvibration, slipping, bunching, or rolling up on itself vis-á-vis theshaft. To overcome these problems, this invention provides a means forintegrally forming a grip to a shaft. This integral formation isaccomplished, essentially, by forming the grip and shaft composite as anintegrated unit and ultimately heating the shaft and grip combination ata desired temperature to integrate both the shaft and grip into one.

[0010] The most common shaft types (wood, metal, plastic) will notoptimally accept heating to combine with a grip. This inventionprovides, in particular, for resin pre-impregnated into fiber, such asgraphite impregnated with epoxy, to be heated and cured together withthe grip and the invention also alternatively provides for a similarintegration with thermoplastic.

[0011] By first wrapping epoxy-impregnated uncured graphite about a heatconductive mandril to form a shaft, a heat susceptible medium isprovided. By next placing the mandril and shaft combination into avacuum tube lined with the grip on the tube interior by evacuating thetube to conform the grip to the tube, the graphite shaft receives thegrip by releasing the vacuum and next providing some pressure on the nowgrip-lined shaft. Thereafter, by heating the shaft and rubber sheathcombination at an appropriate temperature for an appropriate amount oftime, the integration of the shaft and sheath is accomplished byvulcanization. All then that remains is the removal of the mandril fromthe core of the shaft to provide an elongate hollow shaft integratedwith a grip. With this grip provided over the entire shaft orsubstantially all of the shaft, it is also far less susceptible todamage versus the prior art.

[0012] In particular, in a hockey stick, the hockey stick handle is alsoto be provided with a rubberized cuff at one end to receive a bladethereafter in a hollow of the shaft. Prior to this invention, such ashaft/grip combination was not provided in the hockey sports industry.

OBJECTS OF THE INVENTION

[0013] The overall object of the present invention is to provide ahandle and grip means which are integrally formed for a long-handled orshafted device, particularly a hockey stick.

[0014] It is a specific object of the present invention to provide agrip means on an elongate shaft that is not susceptible to slipping anddelamination vis-á-vis the shaft.

[0015] It is another object of the present invention to provide a gripmeans on an elongate shaft that is not susceptible to rolling orbunching on the elongate shaft.

[0016] It is another object of the present invention to provide anelongate shaft, such as a graphite impregnated epoxy-type shaft cookedand cured with a rubber sheath for gripping about the entirety of theshaft to protect the graphite.

[0017] It is another object of the present invention to provide a methodof manufacturing an elongated shaft having a grip means provided aboutits entirety and integrated therewith to cushion sharp blows to theshaft.

[0018] Viewed from a first vantage point, it is an object of the presentinvention to provide a hockey stick, comprising, in combination, ashaft, a blade attached to the shaft, the shaft formed from a compositelayup including a hollow core, and a sheath formed from resilientmaterial ensconcing the shaft.

[0019] Viewed from a second vantage point, it is an object of thepresent invention to provide a method for forming a hockey stick, thesteps including, laying up a composite material, forming the layup ofcomposite material about a mandril defining a layup wrapped mandril,ensconcing a resilient sheath over the layup wrapped mandril,vulcanizing the sheath and layup wrapped mandril combination, removingthe mandril, and inserting a hockey blade hosel in a central core of thelayup formed by removal of the mandril.

[0020] Viewed from a third vantage point, it is an object of the presentinvention to provide a hockey stick, comprising, in combination, ashaft, and a blade attached to the shaft, the shaft formed by laying upa plurality of uncured resin-impregnated sheets of composite material,forming the plurality of sheets about a mandril, defining a layupwrapped mandril, ensconcing a resilient sheath over the layup wrappedmandril, vulcanizing the sheath and layup wrapped mandril combination,and removing the mandril.

[0021] Viewed from a fourth vantage point, it is an object of thepresent invention to provide a shaft for a hockey stick, comprising, incombination, a composite layup including a hollow core, and a sheathformed from resilient material ensconcing the shaft.

[0022] These and other objects will be made manifest when consideringthe following detailed specification when taken in conjunction with theappended drawing figures.

BRIEF DESCRIPTION OF THE DRAWINGS

[0023]FIG. 1 is a perspective view of composite layers on a vacuumtable.

[0024]FIG. 1A is an exploded perspective view of the composite layersshown in FIG. 1.

[0025]FIG. 2A is a side view of a device for wrapping layup about amandril in an open position.

[0026]FIG. 2B is a side view of a device for wrapping layup about amandril in an closed operational position.

[0027]FIG. 3A is a cutaway perspective view of a vacuum pipe and rubbersheath.

[0028]FIG. 3B is the cutaway view of FIG. 3A with a layup wrappedmandril therein.

[0029]FIG. 3C is a perspective end view of a layup wrapped mandrilenshrouded with elastomer.

[0030]FIG. 4 is a front cross-sectional view of that which is shown inFIG. 3C.

[0031]FIG. 5 is a cutaway perspective of a heating chamber.

[0032]FIG. 6 is a side view of a mandril being removed from theinvention.

[0033]FIG. 7 is a perspective view of the invention.

[0034]FIG. 8 is a flowchart of the method of the invention.

DESCRIPTION OF PREFERRED EMBODIMENTS

[0035] Considering the drawings, wherein like reference numerals denotelike parts throughout the various drawing figures, reference numeral 10(FIG. 7) is directed to a hockey stick integrally formed with a shaftand gripping means thereabout according to the present invention.

[0036] The grippable shaft 10 is formed of three main components: layersof a thermoset synthetic material 12; an elastic sheath 30; and a hockeyblade B having a hosel 13.

[0037] As seen in FIGS. 4 and 7, a grippable sheath 30 is integrallyformed with a plurality of fabric layers 12 wherein the fabric layers 12are preferably pre-impregnated graphite epoxy and wherein the sheath 30is preferably then a rubber tube. Whereas the sheath 30 becomesintegrally formed with the fabric layers 12 and the elastic cuff 14 bymeans of a heating and curing process. The elastic cuff is preferablymade of urethane.

[0038] In manufacture, as first depicted in FIG. 1, as a first step,adhesive transfer sheets are removed from sheets 12 to expose the resinthereunder to other sheets 12, save for the uppermost and lowermostsheets 12, where transfer sheets 58 remain temporarily. Next, urethanestrip 14 is added atop the stack and the entire layup 56 is placedwithin vacuum table 48 supported by legs 54. When lid 52 is closed, avacuum is produced via vacuum holes 50, causing sheets 12 and strip 14to be pressed together (had uppermost and lowermost transfer sheets 58not remained, adherence to the lid 52 and/or table 48 would likelyresult). The size of urethane strip 14 is preferably less than both thelength and width of fabric layers 12. More preferably, strip 14's lengthL is as long as the circumference of mandril 18.

[0039] Next, as depicted in FIGS. 2A and 2B, the shaft 10 is formed byfirst providing multiple epoxy-impregnated graphite sheets 12, havingthe remaining transfer sheets 58 now removed, and a urethane or rubberelastomer 14 thereby which are then wrapped about a mandril 18. Thesheets 12 are preferably the graphite type wherein the grains ofgraphite can be a mixture of longitudinal, latitudinal or crossedgrains. That is, each individual graphite sheet 12 may have the same ordifferent grain varieties included. One, for instance, may have graphitestrands all longitudinally drawn. Another sheet 12 may have all thegraphite grains perpendicular to the previous sheet 12. Yet anothersheet or sheets may have the grains of graphite running at variousangles. By utilizing different grain striations on sheets 12, differentshaft strength characteristics can be achieved. By providing a strip ofelastomer such as urethane 14 immediately next to sheets 12, the elasticreceptacle or cuff 14 can later be formed.

[0040] As the strips 12 and elastomer 14, known as layup 56, progressdown the conveyer belt 16 as depicted in FIG. 2B, they are wrappedaround and adhered to a heat conductive mandril 18. Conveyor belt 16 isrotated by motor 22 coupled to pulleys or rollers 20. Likewise, belt 16,also driven by motor 22 when tightened by moving lever 68 along arrow Oand activating tension means 26 and thereby raising arm 28, will therebyrotate mandril 18 around arcuate arrow R and wrap layup 56 about it inturn. Mandril 18 with sheets 12 and urethane 14 wrapped about it is thenremoved.

[0041] As relates more particularly to mandril wrapping machine 100, thedevice is made up of the following. As shown in FIG. 2A, when lever 68is in a resting (or open) position, belt 16 is loosely wrapped aboutrollers 20. Motor 22, coupled to motor wheel 88 by belt 90, will causebelt 90 to turn motor wheel 88, thereby causing belt 92 to likewiserotate wheels 20 via belt 16. Thereafter, when lever 68 is moved in thedirection of arrow O about pivot 80, resulting in the FIG. 2B, tensionmeans of pump 26 causes arm 28 to raise and tension the upper roller 20,thereby tensioning conveyor belt 16 about the plurality of rollers 20.That tensioning causes the belt 16 to tightly wrap around a mandril 18.In particular, when lever 68 is moved along arrow O, the V-shapedcoupling 76 likewise rotates into arcuate notch 78, locking the deviceinto a closed position and tensioning tension support 82 coupled to arm84 when arm 84 likewise pivots about pivot point 86. When tightlytensioned as indicated above, mandril 18 will be caused to rotate aroundarcuate arrow R by belt 16 next to bight 94 as contained by hooked stop70. As the layup 56 is conveyed along belt 16 to mandril 18, layup 56will likewise be tightly wrapped about mandril 18 and held in place byhooked stop 70 at the end of guide arm 84. After, to remove the layupwrapped mandril from apparatus 100, lever 68 is moved in the oppositedirection of arrow O to unlock the device 100 so that the layup wrappedmandril may be removed therefrom. A supporting frame 74 provides a rigidstructure for the above-described apparatus.

[0042] Thereafter, as shown in FIGS. 3A and 3B, the mandril 18 wrappedwith sheets 12 is inserted into an air pressurized sheath 30, which isclamped about a pipe 64 at both ends to cause cavity 72 to be formed. Ascan be seen in FIGS. 3A and 3B, sheath 30 is longer than pipe 64, andonce inserted into pipe 64, the ends of sheath 30 are wrapped back ontothe outside of pipe 64 to be clamped by clamp means 60. Pipe 64,therefore, has an inside diameter greater than the mandril 18 and layup56 combination. The cross-section of pipe 64 can be circular as depictedor any other shape as necessary. The sheath 30 is expanded via an airpressure means 62, or evacuated, to so accommodate the mandril-wrappedshaft. Then the vacuum between sheath 30 and sheets 12 and mandril 18 isreleased from valve 62, so that sheath 30 conforms completely about themandril-wrapped sheets 12 as shown in FIGS. 3C and 4. At this point, thegrippable sheath 30 is frictionally affixed to sheets 12 which arewrapped about mandril 18.

[0043] To further integrate sheath 30 with sheets 12, the combinationmust be allowed to be heated and cured, or vulcanized, as the process isknown, as depicted in FIG. 5 in heating chamber 34. FIG. 5 shows a rack36 of a plurality of the inventions with an inner mandril core 18wrapped with sheets 12 encased in sheath 30 having an elastic receptacle14 combined therewith, ready for heating by element 66. Once heated tothe desired temperature and cooked for the desired period of time, racks36 are removed from oven 34 where the shafts have been vulcanized. Theyare thereafter allowed to cure. For thermoplastics, heating at 350° F.to 550° F. (176° C. to 288° C.) for thirty seconds to ten minutes with asubsequent dwell or hold time to allow bubbles and gases to escape, ispreferred. It may be beneficial to heat the thermoplastic prior toapplying the rubber sheath 30. For epoxies, heating at 150° F. to 350°F. (65° C. to 177° C.) for one to two hours is preferred.

[0044] Once cured and cooled, the mandril 18 can be removed from withinthe core of the sheets 12 by sliding the shaft to a stop 40 and pushingor pulling mandril 18 out from within as depicted in FIG. 6. Thereafter,one has a grip ensconced shaft as depicted in FIG. 7 which may be mated,preferably with a blade B, by inserting blade B's hosel portion 13 intoreceptacle or cuff 14 to form a hockey stick 10. The entirety of thisprocess is depicted in a flowchart at FIG. 8. In one form, the sheath 30ensconces the entirety of the shaft, In another, the sheath 30 initiallyensconces the entirety of the shaft, but later, a few inches are meltedoff during the blade mating process.

[0045] Moreover, having thus described the invention, it should beapparent that numerous structural modifications and adaptations may beresorted to without departing from the scope and fair meaning of theinstant invention as set forth hereinabove and as described hereinbelowby the claims.

I claim:
 1. A hockey stick, comprising, in combination: a shaft; a bladeattached to said shaft; said shaft formed from a composite layupincluding a hollow core; and a sheath formed from resilient materialensconcing said shaft.
 2. The hockey stick of claim 1 wherein saidcomposite layup is comprised of a plurality of graphite sheets.
 3. Thehockey stick of claim 2 wherein said graphite sheets are impregnatedwith resin, and affixed to each other by said resin.
 4. The hockey stickof claim 3 wherein said resilient material runs the length of saidshaft.
 5. The hockey stick of claim 4 wherein said resilient material isrubber.
 6. The hockey stick of claim 5 wherein said layup furthercomprises a urethane sheet.
 7. The hockey stick of claim 6 wherein saidurethane sheet defines an innermost layer of said shaft.
 8. The hockeystick of claim 7 wherein said blade includes a hosel coupled into saidshaft hollow core, said urethane layer overlying said hosel.
 9. Thehockey stick of claim 8 wherein said urethane sheet has a lesser lengththan said graphite sheets.
 10. A method for forming a hockey stick, thesteps including: laying up a composite material; forming said layup ofcomposite material about a mandril defining a layup wrapped mandril;ensconcing a resilient sheath over said layup wrapped mandril;vulcanizing said sheath and layup wrapped mandril combination; removingthe mandril; and inserting a hockey blade hosel in a central core ofsaid layup formed by removal of the mandril.
 11. The method of claim 10wherein said ensconcing includes opening the sheath and inserting saidlayup wrapped mandril.
 12. The method of claim 11 wherein said openingis effected by applying a vacuum on an outside surface of said sheets.13. The method of claim 12 further including placing the vacuum on atube after deploying the sheath in the tube and fixing sheath end at thetube termini.
 14. The method of claim 13 wherein said composite materialincludes a plurality of uncured resin-impregnated sheets.
 15. The methodof claim 14 wherein said vulcanizing includes heating at 150° F. to 350°F. for 30 minutes to 2 hours.
 16. The method of claim 13 wherein saidcomposite material is comprised of a thermoplastic.
 17. The method ofclaim 16 wherein said vulcanizing step includes heating at 350° F. to550° F. for 30 seconds to 10 minutes.
 18. A hockey stick, comprising, incombination: a shaft; and a blade attached to said shaft; said shaftformed by laying up a plurality of uncured resin-impregnated sheets ofcomposite material, forming said plurality of sheets about a mandril,defining a layup wrapped mandril, ensconcing a resilient sheath oversaid layup wrapped mandril, vulcanizing said sheath and layup wrappedmandril combination, and removing the mandril.
 19. The hockey stick ofclaim 18 wherein said blade is attached to said hockey stick byinserting a hockey blade hosel in a central core of said layup formed byremoval of the mandril.
 20. The hockey stick of claim 19 wherein saidensconcing includes opening said sheath and inserting said layup wrappedmandril.
 21. The hockey stick of claim 20 wherein said opening iseffected by applying a vacuum on an outside surface of said sheets. 22.The hockey stick of claim 21 further including placing said vacuum on atube after deploying said sheath in said tube and fixing sheath ends atthe tube termini.
 23. A shaft for a hockey stick, comprising, incombination: a composite layup including a hollow core; and a sheathformed from resilient material ensconcing said shaft.
 24. The shaft ofclaim 23 wherein said resilient sheath runs the length of the shaft. 25.The shaft of claim 24 wherein said resilient sheath is rubber.
 26. Theshaft of claim 25 wherein said composite layup is comprised of aplurality of graphite sheets.
 27. The shaft of claim 26 wherein saidgraphite sheets are impregnated with resin and affixed to each other bysaid resin.
 28. The shaft of claim 27 wherein said layup furthercomprises a urethane sheet.
 29. The shaft of claim 28 wherein saidurethane sheet defines an innermost layer of the shaft.
 30. The shaft ofclaim 25 wherein said composite layup is comprised of thermoplasticmaterials.
 31. The shaft of claim 30 wherein said layup furthercomprises a urethane sheet.
 32. The shaft of claim 31 wherein saidurethane sheet defines an innermost layer of the shaft.
 33. An apparatusfor wrapping a layer about a mandril, comprising, in combination: a belthaving a first surface to support the layer; said first surfaceincluding tension means to constrain the mandril within a bight portionof said belt; means to release the mandril upon relaxing said tensioningmeans; whereby the layer, when placed on said first surface, and whensaid tensioning means is enabled, wraps on the mandril, furthercomprising a frame wherein said belt is rotatably coupled to said frame,a lever pivotally coupled to said frame and said tensioning means forenabling and disabling said tensioning means, and a guide arm pivotallycoupled to said frame and movably coupled to said lever to furtherfacilitate constraint of said mandril.
 34. The layer wrapping apparatusof claim 33 wherein said belt is a closed loop belt.
 35. The layerwrapping apparatus of claim 34 further comprising a motor means drivablycoupled to said belt.
 36. The layer wrapping apparatus of claim 35further comprising rotating means rotatably coupled to said belt forrotating said belt.
 37. The layer wrapping apparatus of claim 36 furthercomprising a hooked stop coupled to one end of said guide arm, the sameend facilitating the constraint.
 38. The layer wrapping apparatus ofclaim 37 wherein said rotating means are driving rollers.
 39. Anapparatus for making tubular articles from pliable sheets, comprising,in combination: a frame; a lever pivotally coupled to said frame; aguide arm having a hooked stop at one end, said guide arm pivotallycoupled to said frame and movably coupled to said lever; a closed loopwrapping belt supported on said frame by tension and driving rollers forconveying said pliable sheets, said wrapping belt guided by said hookedstop; a bight portion of said wrapping belt to form a working gap behindsaid hooked stop; an elongated mandril seated in said gap; means todrive said wrapping belt; means to tension said wrapping belt to rotatesaid mandril, said means coupled to said lever.